Morooka MST2200 MST2500 MST3000 MST4000 Operation and Maintenance Manual

MEAM 22000100

RUBBER CRAWLER CARRIER MST-2200 MST-3000

Operation

MST-2500 MST-4000

Maintenance Manual

Engine Parts for Morooka Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine. This manual should be kept with the machine for reference and periodically reviewed by all personnel who will come into contact with it.

Serial numbers MST-2200-22001 MST-2500-2510 l MST-3000-3000 I MST-4000-4000 l and up

FOREWORD

FORE'\JVORD Thank you for purchasing this machine.

This manual describes procedures for operation, handling, lubrication, main­ tenance, checking, and adjustment. It will help the operator_ realize peak perform­ ance through effective, economical and safe machine operation.

• Please read this manual carefully BEFORE operating the machine.

• Please continue studying this manual until proper operation is completely reinforced into personal habit.

*

Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority. Safety precautions are indicated with marks in this manual.

A

-1-

BREAKING IN YOUR NEW MACHINE

BREAKIN

IN YOUR NEW

ACHINE

Each machine is carefully adjusted and tested before shipment. However, a new machine requires careful operation during the first 100 hours to break in the various parts. if a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the service life will be reduced. A new machine must be operated with care, particularly with regard to the following items. @l

@

6iil

@

After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation.

Avoid operation with heavy loads or at high speeds.

Sudden starting or acceleration, un­ necessarily abrupt braking and sharp turning should be avoided.

At the first 100 hours of opera­ tion , the machine should be maintained in the following manner:

1) Replacement of all oil, traveling moter and hydraulic oil.

2) Check and retighten the nuts and bolts.

*

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( For replacement procedure, refer to EVERY 300 HOURS SERVICE, EVERY 500 HOURS SERVICE EVERY and HOURS 600 SERVICE).

When replacing oil filter elements (cartridges), check their interiors for dirt and dust. If heavily collect­ ed, check for possible cause before starting operation.

CONTENTS OPERATION

·A.. . . . . . . . . . . . . . . . . . .

SAFETY Hl�TS · · GENERAL LOCATIONS · · · · · · · · · · · · · · · · · · · · SPEC! FICATIONS ....................... .

OPERATOR'S COMPARTMENT ..............

INSTRUMENTS AND CONTROLS ..............

CHECK BEFORE STARTING ................

OPERATING YOUR MACHINE ...............

TRANSPORTATION ......................

HANDLING OF BATTERY ..................

COLD WEATHER OPERATION ..............·.

4 11 12 13 15 23 25 31 32 35

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MAINTENANCE PERIODIC MAINTENANCE .. .. ...... .....

PRECAUTIONS FOR MAINTENANCE .... . .

MAINTENANCE�TABLE .... . ... . ... ....

INITIAL 25 HOURS SERVICE. ....... . ...

EVERY 25 HOURS SERVICE.............

INITIAL 100 HOURS SERVICE ...........

EVERY 300 HOURS SERVICE............

EVERY 500 HOURS SERVICE............

EVERY 600 HOURS SERVICE............

ADJUSTMENT ...................... · .

TROUBLE SHOOTING GUIDE. .............

STORAGE ....... . ... . ...............

FUEL, COOLANT AND LUBR !CANTS ........

39 40 43 45 45 46 46 47 48 49 52 54 56

GENERAL

SAFETY HINITS

Wear wel I-fitting hard hat, safety shoes and working clothes. Never wear loose or unbuttoned clothes as they may catch on protruding parts of machine. Never wear clothes covered in oil.

If the nature of the work so requires, wear protective goggles or mask, ear plugs or other protection.

• Accidents or injuries are liable to occur when the operator is careless or inattentive. It is most important to bear safe operation in mind at all times..

• Do not overwork or drive after drinkirig. Take care of your health.

Driving while unfit can lead to mistakes in judgement in emer­ gencies.

• Never allow more than the permit­ ted number of persons to ride on the machine. @

e

e

@

A

• Learn the prohibitions, precautions and rules about work procedures in the job site. Make every effort to· prevent accidents by always follow­ ing these and always bearing safety in mind.

• If there should be an accident or fire or any other such unexpected mishap, deal with it quickly, using the nearest apparatus. In addition, it is necessary to prevent any secondary mishaps. It is also important to know the emergency contact system.

• Learn beforehand the locations and method of use of emergency equip­ ment such as first aid boxes, fire extinguishers or other fire-fighting equipment. � Learn how to use the control devices, gauges and warning devices.

Be sure you understand the meaning of the caution plates and

-4-

other signs. Remember the check points and checking method for engine oil, fuel, cooling water and hydraulic oil levels. Always know the dimensions and capacity of your machine.

• Fuel, oil and anti-freeze are dangerous. Never smoke or I ight matches when handling fuel, oil, grease or anti-freeze. Do not handle these substances near any fire or flame. When selecting a place for storing them, take care to choose a place away from where fire is used.

• Exhaust gas is dangerous. When running the engine for long periods in a poorly ventilated area, there is a danger of gas poisoning, so open the windows or doors to ensure a good supply of fresh air.

• When operating inside a building always be sure of the clearances of the ceiling, entrances, aisles, etc. and the load limit of the floor.

BEFORE STARTING OPERATION

• Examine the lay of the land and the kind of soil at the site to determine the dangerous points and the best method of operation. Proceed with the work only after making· safety arrangements about the dangeous points. Avoid operating near cliffs or deep gullies. Be particularly care­ ful of the edge of cliffs, falling rocks or landslides.

• Always carry out inspection and maintenance correctly. Check for leakage of fuel, lubricant or hydraulic oil, and for loose, broken or missing parts.

If there are any such problems always correct them. Never use the machine without correcting all problems.

Use repaired machines only after receiving permission from the serviceman in charge of the repair.

• Adjust the operator's seat until it is in the most comfortable position for operating.

• When getting on or off the machine, use the handrail and step provided. Do not jump up or down from the machine.

• Learn about the safety devices on your own machine and about how to use them. Confirm that they are correctly attached in the prescrib­ ed position.

• Before starting the engine, confirm that all control levers are in "NEUTRAL" .

• To ensure the safety of workers near the machine, always signal or sound the horn to warn them before starting the engine, moving the machine or turning.

Be particularly careful to check that the rear is dear before backing the machine.

• Do not leave parts or tools lying around in the vicinity of or on the floor of the operator's compart­ ment. Keep everything in its proper place, to avoid any hindrance while driving.

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• Wipe off thoroughly any grease, oil or mud on the step, handrail, floor or control levers. Failure to do this may cause you to slip.

• Check the level of the fuel, lubri­ cants and cooling water. Do not smoke or use naked flames when checking. Extinguish· cigarettes before checking or refilling. Check that the radiator cap and all oil filler caps or plugs are firmly tightened.

• When there is a leader, fix standard signals and always follow these signals when operating. Learn the signs and rules used in the job site and always follow them.

• Inspect te inside of the engine room and remove any dead leaves or paper.

Dead

leaves or paper are

highly inflammable and can cause fires.

e Before starting operations, start the engine and do the following. o Check that all gauges are work­ ing properly o Check the play and travel of each lever and pedal o Operate the work equipment and check that it is working properly o Drive the machine slowly in a safe place and turn the machine to the left and right to check that the steering system is work­ ing properly. o Check that the exhaust gas color is normal o Check that· there is no abnormal noise or vibration

DURING OPERATION

e When operating, work slowly and carefully. Do not rush your work.

Fast operation may look efficient, but it is dan�Jerous and leads to breakdowns. So in the long run it is not efficient.

• The work area should always be kept flat. This increases operating efficiency and makes driving smooth.

• When driving, sit in the operator's seat correctly so that the truck can be operated properly.

During while not sitting in the operator's seat, or driving while standing are dangerous.

• Do not travel with the door opened.

-6-

e Always concentrate. It is extremely dangerous to allow yourself to be distracted or to think of other things when operating a machine.

Always pay attention to your driv­ ing, and to your surroudings.

In dangerous places, or where there is restricted visibility, it is important to get down from the machine and confirm whether it is safe before continuing work.

• When stopping at junctions, to avoid collisions with other vehicles, keep your distance and confirm who has priority.

• Be careful of those around you, and always confirm that there is no person or obstacle in the way before driving or turning machine. e When traveling down hill, adjust the speed with the travel lever and fuel control lever.

• The machine condition can be judg­ ed from many factors. Changes in the gauges, sound, vibration, ex­ haust gas color or response of the control · levers can indicate the occurrence of some disorder. If any disorder occurs, park the machine immediately in a safe place and appropriate take action.

Be especially careful in the case of fuel leaks as there is danger of fire.

•· Do not allow. unauthorized persons to enter the work area.

• Always consider the weight of the • machine when driving on roads in snow or rain, or on muddy· or soft terrain. Be careful to avoid the tires slipping or sinking into the ground. f» When towing a broken-down machine, first check that the brakes are working properly, then connect the machine with a suitable tow­ rope or cable. When towing on roads, always follow traffic regula­ tions and attach a correct warning sign.

• The machine s;hould alway be operated at a speed where it can be correctly controlled. The following are dangerous.

Speeding Snaking Coasting • Never leave the operator's seat without switching the engine off.

• Before crossing bridges, confirm that the bridge is strong enough to take the weight of the dump truck.

• When continuin�r operations after rain� remember that conditions may have changed from those before the rain, so proceed with caution. Be particularly careful when approach­ ing the shoulder of the road or cliffs, as they may have been loosened by the rain.

* * *

-7-

AFTER OPERATION @ When parking the machine, park it in a safe place outside the working area, or in the specified place.

The following factors should be considered when choosing a parking place: It should be on flat, firm ground where there is no danger o-f rockfalls, landslides or floods.

• When the machine has to be parked on a slope, chocks must always be placed under the tracks.

When operating on uneven ground or in palces where there are obstacles, remember the following points: • When operating on uneven ground, drive at as low a speed as possible and avoid sudden changes in direc­ tion.

• Wherever possible, avoid travelling over large rocks, fallen trees, tree stumps and other such obstacles.

Either use the working equipment to remove them, or travel round them.

When operating at the edge of a cliff or on the shoulder of a road, remember the following points: • When operating in a place where there is danger of the machine falling over tlhe side, be doubly careful. Do not approach the edge of the cliff or road shoulder by mistake.

• When working on river embank­ ments or other places made of piled soil, there is the danger that the weight or vibra1tion of the machine may cause the machine to sink into the piled soil, so be extremely careful when operating in such places.

• When driving at the side of a road where there is danger of the ground collapsing, use the tracks· left by previous machines. If the ground starts to sink, stop and reverse out immediately. It is important to check the strength of the road shoulder before driving on it.

-B-

When on operating slopes, remember the following points: • When driving on a slope, always drive directly up or down it. Never drive horizontally or diagonally across the slope, as this may cause the machine to roll over or slip side­ ways.

• When going down a slope, use the engine as a brake. If this is not enough to control the speed of the machine, use the steering brake as well.

• As far as possible, avoid turning the machine on a slope. It may cause the machine to roll over or slip sideways.

* @

Do not mount wooden or iron plate, fallen trees or logs. Piles of leaves or branches are also very slippery, so proceed with caution.

Before going up or down a slope, select a travel speed most suited to the slope.

When operating1 in water or in muddy areas, remember the following points.

• When operating in water or when crossing shallows, first check the bed soil condition and the depth and flow speed of water, then proceed, taking care not to go beyond the permitted depth.

• If the machine g1ets stuck in mud, it is completely useless to increase the engine speed, causing the tracks to spin, or to rock the machine back­ wards and forwards. In such a case, reduce the load if possible, and drive out slowly.

• When passing through a narrow space, be careful of the side and overhead clearances. Take special care not to touch any obstacles on either side or overhead. If neces­ sary, have someone outside the machine call.

• When working near electric cables, move the cables if possible. If this is difficult, erect barriers around the cables to prevent electric shock, or insulate the cables and observe the following precautions.

Always remember there is a danger of electric shock, so never touch the1 electric cables.

Always wear shoes with rubber or leather soles.

Appoint a special supervisor to ensure adequate supervision.

Standing too near electric cables may cause electric shocks from sparks. The following table shows the minimum safe distances for different voltages. Do not go closer than these distances.

*

*

* *

Voltage (No. of insulators)

6.6 KV (Wires only)

33.0 KV (1 - 3) 66.0 KV (5 - 8)

154.0 KV (10 - 18)

* -9-

275.0 KV (16 - 30)

/ I

Standard min. safe distance 3m

4m

5m Sm

10m

Learn action to be taken in case of electric shock.

When operating at night, remember the following points: Be sure to arrange an adequate lightening system. @ At night it is very easy to make mistakes in assuming the distance and height of objects and land. @ When operating in fog, mist or smoke, where visibility is bad, be especially careful to confirm first whether operation is safe.

When visibility drops below safety level, stop work and wait for the visibility to improve.

*

When operating in snow, or clean­ ing snow, remember the following points: • Even slight slopes can cause un­ expected side slipping, so in such places, operate with extreme caution.

• Take care not to overload the dump body. Overloading shortens the service life of the truck.

• When backing to dump a load, be careful not to back too far. Place blocks or build a small ridge to stop the tracks at the dumping point.

• Never drive with the dump body raised. Always lower the body before moving .

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• Loading

Be sure to load the dump truck evenly.

GENERAL LOCATIONS

GENERAL LOCATIONS 1.

2.

3.

4.

Travel and steering lever Dump control lever Rear id !er Dump cylinder

5. Rubber crawler 6. Operator's seat 7. Head lamp

8.

9.

10.

11.

12.

13.

Hood Fuel tank Hydraulic oil tank Drive sprocket Track rollers Dump body

8

3

/; 1/// ��

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//

l,/ �-'\

',

9 10 11

6 - 11 -

SPECIF !CATIONS

SPECIFICATIONS MACHINE MODEL

MST-2200

MST-2500

MST-3000

IVIST-4000

12,250

14,500

19,520

20,500

Max. 10/15

Max. 9/12

Max. 7 /10

Max. 6/8

10,000

'!2,000

15,000

20,000

3.52

4.4

5.85

8.19

57

57

57

57

CATERP! LLAR 3306T

MITSUBISHI 6O22T

ISUZU

6RB1-T

CATERPILLAR 3406T

(HP)

250

261

296

360

(rpm)

2,200

2,200

2,100

2,100

OPERATING WEIGHT (kg) TRAVEL SPEED (Low/High) (km/h) MAX. LOADING CAPACITY (kg) DUMP BODY CAPACITY (STUCK) (m 3 ) GRADE ABI UTY (%) ENGINE MODEL

FLYWHEEL HORSEPOWER

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Morooka MST2200 3306DIT Engine Maintenance Kit # 111-8016 Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts, glow plugs.

Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, Reinstall valve covers with new valve cover gaskets, Replace filters, Replace V-belts, Replace glow plugs,

Morooka MST2500 Mitsubishi 6D22 6D22T5 Engine Maintenance Kit # ME051718 Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts, Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, Reinstall valve covers with new valve cover gaskets, Replace filters, Replace V-belts,

Morooka MST3000 Isuzu 6RB1-T-TPF02 Engine Maintenance Kit # 1-11173010-2 Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts, glow plugs.

Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, Reinstall valve covers with new valve cover gaskets, Replace filters, Replace V-belts, Replace glow plugs,

Morooka MST3000 3406T Engine Maintenance Kit # 111-8019 Includes: thermostat set, thermostat gaskets, valve cover gaskets, oil filters, air filters, fuel filters, V-belts, glow plugs.

Replace thermostats and thermostat gaskets, Adjust intake valve clearance and exhaust valve clearance, Reinstall valve covers with new valve cover gaskets, Replace filters, Replace V-belts, Replace glow plugs,

Engine Parts for Morooka Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

PERA

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PARTMENT

OPERATOR'S COMPARTMENT

(MST-2200)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

- ·13: -

Dump lever Horn switch Ammeter Tachometer Hour meter Engine oil pressure warning lamp Engine water temperature gauge Fuel control lever Travel and steering lever Starting switch Travel speed high-low selector switch Engine stop switch Flasher switch Lamp switch HST oil pressure warning lamp Parking brake lever

OPERATOR'S COMPARTMENT

(MST-2500)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

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Dump lever Engine oil pressure gauge Horn switch Ammeter Tachometer Hour meter Engine water temperature gauge Parking brake lever Fuel control lever Engine oil pressure warning lamp Starting switch Travel and steering lever Engine stop lever Travel speed high-low selector switch Resistor Flasher switch Lamp switch Main switch HST oil pressure warning lamp

INSTRUMENTS AND CONTROLS

STARTING SWITCH

INSTRUMENTS AND CONTROLS

KEEP TH[ K[ y ON A >rrn START :"'i OFF ING

'f"\t.-1>-

•

01\1

�____.___ � , "- J'_,...

11!1-1-1) .,,_

MAIN SWITCH

ON Charging and lamp circuits activate.

Keep key at ON after starting.

START At this key position, the starting motor will crank the engine. Release key immediately after starting.

OFF Key insertion-withdrawal position.

None of electrical circuits activate.

HEAT Use this position when starting In cold weather.

Release the key to allow it to return automatically to OFF and then, without delay, turn it to START. When starting, be sure to use the starting key.

*

- 1!3 -

This switch is used to cut the power sourse.

G) Power sourse OFF. ® Power sourse ON. Applicable to MST-2500, 3000 and 4000.

*

INSTRUMENTS AND CONTROLS

ENGINE WATER TEMPERATURE GAUGE

ENGINE Oil PRESSURE GAUGE

AMMETER

This shows the temperature of the engine cooling water. ° It should indicate 75 to 85 C during normal operation. ° If the indicator goes above 100 C during operation, cut the load and run the engine at low idling until the temperature drops.

When the indicator is in the green range during operation, engine oil pressure is normal.

When the indicator moves outside the green range, run the engine at low idling speed until the engine oil pressure goes down.

The center range indicate the battery is being charged; the red range indicates the · battery is being dis­ charged.

When the indicator comes to the red range, check the cause.

*

Applicable to MST-2500 and 3000.

-16-

INSTRUMENTS AND CONTROLS

TACHOMETER

HOUR METER·

RESISTOR

This shows the revolutions per minute of the engine.

This meter shows the total opera­ tion hours of the machine.

This signal is red-heated after the starting switch is turned to HEAT, thus indicating the electrical intake air heater is heated.

The analog type tachometer applies to MST-2500 and 3000.

The digital type tachometer applies to MST-2200 and 4000.

-17 -

INSTRUMENTS AND CONTROLS

ENG!NE Oil PRESSURE

WARNING LAMP

It is normal that the lamp does not light during machine operation.

Lighting of the lamp during opera足 tion indicates a low engine oil pres足 sure. Stop the engine immediately and check for engine oil pressure.

HST Oil PRESSURE WARNING LAMP

TRAVEL SPEED HIGH-LOW SELECTOR SWITCH

It is normal that the lamp does not light during machine operation.

This switch is used to select the travel speed.

Lighting of the lamp during opera足 tion indicates a low HST oil pressure.

Stop the engine immediately and check for HST charging circuit.

-18-

G)

速

Travel speed HIGH Travel speed LOW.

INSTRUMENTS AND CONTROLS

HORN SWITCH

LAMP SWITCH

FLASHER SWITCH (�)

(j)

---;--1--2 �

Push the button to sound the horn.

This switch operates the turn signal

The head lamps I ight by moving the lighting switch knob as shown.

Position ·1: Head lamps at low beam Position 2: Head lamps at high beam

- 19-

lamps.

CD RIGHT TURi\l

®

LEFT TURN

INSTRUMENTS AND CONTROLS

ENGINE STOP LEVER

ENGINE STOP SWITCH

TRAVELING AND STEERING LEVER

·cf;.-·1·.. �\- G,. ·.i, . ·.

@

r-:-'--,

;-::-®· ,,, -�

. ·-.. . .

® Pull the lever to stop the engine.

Push it to return it to the operating position.

Applicable to MST-2500 and 3000.

*

Push the button to stop the engine.

Applicable to MST-2200 and 4000.

*

-20-

·._

·.

:

·.

2�--::-, (I;

---= . .'

.,_.·

_.

..

A

\

®

The traveling and steering lever is used to operate the left and right travel motors.

CD Forward: Pu:;h the lever forward. ® Reverse: Pull the lever backward. ® Left pivot turn (forward) @ Right pivot turn (forward) :�) Neutral: Parking brake is applied and the machine stops.

INSTRUMENTS AND CONTROLS

FUEL CONTROL LEVER

CD

®'

®0==1

This lever is used to control the engine speed and output.

CD Engine stop position: Push the lever fully. ® Low idling position: Pull the lever from engine stop position CD until you feel the operating force falls off. ® High idling position: Pull the lever fully from low idling position ®.

DUMP LEVER

PARKING LEVER

CD

®

®(�

®,f_ -.--- -

�

This lever operate brake.

CD PARKING Cl) RUNNING

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the

parking

CD

!)'/\> ;;J. .

.-

The dump lever is provided to shift the dump body position.

Lever position: CD RAISE ® HOLD The dump body is kept held where it is. @ LOWER

INSTRUMENTS AND CONTROLS

FUSE

* Fuses serve to protect electrical parts and wiring from getting burnt out because of excessive current. If white powder appears on the fuse surface because of corrosion, replace the fuse.

When replacing a fuse, remove the cover by turning it in the direction of

Applicable to MST-2500 and 3000.

Fuse Terminal capacity mark A

15A

Head lamp, Engine oil pressure charging lamp

B

15A

Turn signal lamp, Horn

C

15A

the arrow.

A

the

electrical system

from the power source or place the

Engine oil pressure gauge, Engine water temperature gauge

D

15A

Tachometer, Hour meter

E

15A

HST oil pressure charging line

Before replacing a fuse, be sure to disconnect

Circuit

*

Applicable to MST-2200 and 4000.

Fuse Terminal mark capacity

A

15A

Head lamp, Parking indicator line, HST oil temperature indicator line

B

15A

Turn signal lamp, Horn

C

15A

Engine water temperature gauge

D

15A

Hour meter, H-L speed selector line

15A

HST oil pressure charging line, Engine oil pressure charging line

E

starting switch key in OFF.

-:22 -

Circuit

CHECK BEFORE STARTING

CHECK BEFORE STARTING

Pre-operation checks forestall machine trouble. Never neglect them. a. Walk around the machine and check for any trace of oil or water leakage. Examine connections of high pressure hoses, hydraulic cylinders, final drive and radiator with special attention.

If any leakage is evident, check for the cause and repair. b. Check tightness of bolts and nuts, and retighten if required. Particular checks are required for mounting of air cleaner and muffler. c. Check for broken electric wirings, short circuits and �oose terminals.

d. CHECK AND REFILL COOLANT

CD

Remove radiator cap ( 1) and check that the coolant level is in the shaded area. If level is low, add water. If move water than normal is required to fill up to the spec[fied level, coolant is considered to be leaking somewhere.

Immediately locate the leak and plug it.

- 23 -

Aoo·

not remove c�p (1) while cooling water is hot. Hot water-may spout out.

When removing cap ( 1), tum it slowly to relieve inner p ressure.

./

e. CHECK DUST INDICATOR When air cleaner element is clogged, the red piston of dust indicator ( 1) reaches service level and gets locked.

In the case, clean element.

After cleaning element, push the button to return red piston.

CHECK BEFORE STARTING

f. CHECK FUEL LEVEL

g. CHECK 01 L LEVEL IN ENGINE OIL PAN

1. Check the fuel level using sight gauge ( G) on the side face of the tank.

2. Upon completion of work, pour in additional fuel from filler (F) until the fuel tank is full.

Refer to the section "FUEL, COOLANT AND LUBRICANT".

1. Use the dipstick (G) to check the oil level.

2. The oil level should be between mark L and H, if necessary, add oil at the oil filler (F).

Stop the engine when checking the oil level.

Make an oil level check before starting engine or 15. minutes or more after the engine is stopped.

If oil remains at various portions of the engine, the correct oil level cannot be measured.

*

* *

-24 -

h. CHECK TRAVELING MOTOR AND TRANSMISSION PUMP FOR NOISE i. CHECK TRACK TENSION

PERATIN

TO START THE ENGINE

BEFORE STARTING pre-operation Perform refering , to the section BEFORE STARTING.

Y()UR MACHINE

OPERATING YOUR MACHINE

checks CH ECK

2. Turn starting key (2) to the ST ART position. "\

0�\>-,

1. Pull fuel control lever ( 1) a I ittle towards you from the low idling position.

3. When engine is started, release starting key (2) and the key will return automatically to ON.

'\ 0�\

-25 -

OFF I

91\/ /-�'

,

/ .,,"'7--?/' u'/'

OPERATING YOUR MACHINE

CHECKS AFTER STARTING

* * * *

If engine will not start, repeat the starting procedure after about 2 minutes.

Do not leave the key in START for more than 20 seconds.

Do not put the key in OFF position while the engine is running.

To start the engine in cold weather, refer to COLD WEATHER OPERATION.

After starting, make the following checks.

2. After warm-up run is completed, check gauges and caution lamps for proper operation.

3. Check if the exhaust color is normal or whether there is any abnormal noise or vibration.

Avoid abruptly accelerating the engine until the completion of warm-up.

*

1. Pull fuel control lever (1) and run the engine at medium speed.

Then run the engine at no load for about 5 minutes.

- 26-

OPERATING YOUR MACHINE

STOPPING THE ENGINE

For MST-2500 1. Cool the engine by running it at low idling speed for about 5 minutes. if engine is stopped abrupty before it cools down, engine life may be greatly shortened.

Never stop engine abruptly except in case of emergency.

Especially when the engine is overheated, allow the engine to idle without immediate stoppage so that the engine is gradually cooled down to be ready for proper stoppage.

*

For MST-2200 2. Pull the engine stop lever (1) to stop the engine.

Applicable to MST-2500 and 3000.

*

*

-27 -

3. Push the engine stop button (2) to stop the engine.

Applicable to MST-2200 and 4000.

*

OPERATING YOUR MACHINE

TO MOVE THE MACHINE OFF

Before starting the machine, confirm the safety around the machine, and make a signal.

1. Bring the work equipment in the traveling posture.

2. Pull fuel control lever to increase engine speed.

3. Slowly incline traveling and steering lever in the forward or reverse direction, and move off. , r

.

•.----------

..... __ ./____ --

,,

-·­.. - --

' .... _,,, ,------

High idling

A Avoid

......,,.

----·

-ir------.. ___:

Forward

Reverse

abrup ty operating the traveling and steering lever with the fuel control lever fully open, as this will cause the machine to move off suddenly.

-28-

OPERATING YOUR MACHINE

CHANGING DIRECTION • When changing the direction of a running machine

• When performing cou nterrotation

, ... '

' �

\I l

Operate the traveling and steering lever in the following manner.

I I I j I I I :

.. :'�i� .__ .."; I I I

' I I I I ' I I

\

,.,,..

l>

,,

When making a left turn, inclin!;? the traveling and steering lever forward.

Then incline the lever to the left.

In the case of a right turn, incline the traveling and steering lever to the right in a similar manner to the above.

*

-29'-

To counterrotate the machine to the left, incline the traveling and steering lever to the left.

In the case of a right turn, incline the traveling and steering lever to the right.

Avoid abruptly changing the di­ rection of the machine as far as pos­ sible. In particular, before counter­ rotating the machine, first bring it to a halt.

*

*

OPERATING YOUR MACHINE

TO STOP THE MACHINE 1. Put the traveling a nd steering lever in the neutral position.

2. Lower the engine speed using fuel control elver.

High idling

-30-

*

A

To stop the engine refer STOPPING THE ENGINE.

to

When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidab­ ly necessary to park the machine on a slope, insert blocks underneath track rubbers.

TRANSPORTATION

TRANSPORTATION

When transporting the machine, observe the various road rules, road trans­ portation vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain a special platform for loading and unloading the machine. When it is un­ avoidably necessary to use ramps, however, at the least observe the following for safety.

1. Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move. Then fix the ramps in I ine with the centers of the trailer and the machine.

Make sure the ramps have suffi­ cient width, length and thickness to enable the machine to be safely loaded and unloaded.

If the ramps sag appreciably, rein­ force it with blocks, etc.

2. Determine the direction of the ramps, then slowly load or unload the machine.

*

ARemove the mud from the un­ dercarriage to pn:1vent the machine from slipping to the side on slopes.

3. Load machine at a suitable place on trailer. To prevent machine from moving during transportation, hold it securely in place by applying blocks to front and rear of track rubber and by fastening machine with chain or wire rope. Secure machine with special care to prevent shifting sideways.

A Never change travel direction on

the ramps. When changing direc­ tion, back up off the ramps and change direction on ground.

- 31 -

4. Keep various control lever in the following place e Fuel control lever in Engine low idling position Take off the starting key.

Determine the route for trans­ porting the machine by taking into account the width, height and weight of the machine.

*

.A when loading the machine, pairk the trailer on a flat firm roadbed.

Keep a fairly long distance !between the road shoulder and the machine.

HANDLING OF BATTERY

HANDLING OF BATTERY PRECAUTIONS FOR CHARGING BATTERY 1. Before charging, disconnect the cable from the negative (-) terminal of the battery. Otherwise, an unusually high voltage will damage the alternator.

2. While charging the battery, remove all battery plugs for satisfactory .ventilation.

To avoid gas· explosions, do not bring fire or sparks near the battery.

3. If the electrolyte temperature ° exceeds 45 C, stop charging for a

6. Do not mix up cables (positive (+) to negative (-) or negative (-) to positive (+)), as it will damage the

while.

4. Turn off the charger as soon as the battery is charged.

Overcharging the battery may cause followings: 1) Overheating the battery 2) Decreasing the quantity of elec· trolyte.

3) Damaging the electrode plate 5. If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water.

-32-

alternator.

7. When inspecting or serv1c1ng a battery, be sure to stop the engine and turn the starting switch to "OFF" position.

8. When performing any service to battery besides checking the elec­ trolyte level or measuring the specific gravity, disconnect cables from the battery.

HANDLING OF BATTERY

REMOVAL AND INSTALLATION OF BATTERY • When removing battery, first dis­ connect the cable from the ground (normally, from the negative (-) terminal). If a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted.

• When installing battery, the ground cable should be connected to the ground terminal as the last step.

STARTING ENGINE WITH A BOOSTER CABLE When starting up the engine with a booster cable, do as follows:

1. Before connecting the booster cable 1) Size of booster cable and clip should· be suitable for the battery size.

2) Check cables and clips for breaks, corroded surfaces, etc.

3) Make sure cables and clips are firmly secured.

4) Keep the starting switch in "OFF" position.

5) The battery of the running engine must be the same capacity as that of engine to be started.

2. Connect the booster cables in the following manner.

1) Connect one clip of booster· cable A to the positive (+) terminal of the engine to be started.

2) Connect the other clip to the positive (+) terminal to the engine which is running.

3) Connect one clip of booster cable B to the negative (-} terminal of the engine which is running.

4) Connect the other clip to the body of the machine to be started.

Make sure the clips are firmly connected to battery terminals.

Then, start the engine.

*

®

\{( CD �

(")

II>

11

f:J

ry

Battery for running engine

@

Battey for engine to be started @

Body of the machine to be started

-33-

()

II

2'

2

r �

HANDLING OF BATTERY

Awhen connecting the cables, never

contact the positive negative (-) terminals.

( +)

and

AMake sure that the booster cable

connections are correct. Connect the booster cable to the body as far as possible from the battery.

After the engine has started, the booster cables should be disconnected in the reverse order in which they were connected.

1. Disconnecting the booster cables 1) Disconnect the clip of booster cable B from the body of the machine which was started.

2) Disconnect the other clip from the negative (-) terminal of the . . running engine.

3) Disconnect the clip of booster cable A from the positive (+) terminal of the running engine.

4) Disconnect the other clip from the positive (+) terminal of the engine which was started.

3. Starting the engine 1} Turn the starting switch to START position and start up the engine.

2) If the engine doesn't start at first, try again after 2 minutes or so.

® e

CZ) Battery for running engine

Pl®

Battery for engine which was started CD � Body of the machine which was started

-34 -

@

COLD WEATHER OPERATION

COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE • Replace lubrication oil by that with pre6cribed viscosity. � Fuel of low pour point shall be used. ASTM 0975 No. 1 diesel fuel should be used at atmospheric tem­ ° perature lower than -10 C.

• Add antifreeze in the cooling water.

When the atmospheric temperature ° drops loyver than 0 C while the machine is stopped, prevent freez­ ing by adding antifreeze to the cooling water. The mixing rate of antifreeze is determined according to the expected minimum tempera­ ture. The following table shall be used.

Mixing rate of water and antifreeze Min. atmospheric temperature o ( C)

-5 -10 -15 -20 -25

Antifreeze

23

(%)

30

-35-

36

41

46

*

1) 2) 3)

4)

Cautions for using antifreeze Perm�nent type antifreeze shall be used.

Soft water (ex: city water) shall be used as mixing water.

Cooling systems must be thorough­ ly flushed before filling with anti­ freeze mixture.

When the climate becomes warmer and antifreeze (except permanent type) is not needed, replace with soft water (ex: City water) after perfectly cleaning the cooling system.

A Take

care for fire as antifreeze is inflammable.

COLD WEATHER OPE.RATION

Care in using antifreeze Use a Permanent Antifreeze {ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard requirements as shown below. With permanent afltifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information.

Standard requirements for permanent antifreeze · SAE ............... J1034 · FEDERAL STANDARD ..........· ......0-A-548D Never use any antifreeze made from methyl alcohol or ethyl alcohol which may be a cause of engine trouble.

*

*

Where no permanent antifreeze is available, an ethylene glycol anti­ freeze without corrosion inhibitor may be used only for the cold season. In this case, coolant must be changed two times a year {at the beginning and at the end of the cold season ).

Do not mix an antifreeze with one of different brand.

Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed with an antifreeze.

• Battery As ambient temperature drops, battery capacity will drop, and electrolyte may sometimes freeze if battery charge is low. Maintain battery at a charge level of approx.

100% and insulate it against cold temperature so that machine can be readily started the next morning.

*

Measure specific gravity of flu id and obtain rate of charge from the following conversion table: d

°

°

20 c

0 C

°

°

-10 C -20 C

e �

*

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

*

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

-36-

*

When electrolyte level is low, add distilled water in the morning be­ fore work instead of after the day's work.This is to prevent fluid from freezing at night.

COLD WEATHER OPERATION

CAUTIONS AFTER COMPLETION OF WORK

AFTER COLD WEATHER When

1. Mud and water on the machine body

be

should

completely

removed.

2. Drain water collected in fuel system so that such water may be frozen at

ambient

park

battery

the

machine

on

wooden

boards. This will prevent the ac­ cessories

from

freezing

to

the

next

temperature, or remove

the

position rods.

Such droplets must be fully wiped off because if water is frozen to the rod when the cylinder is uti Iized, seals

may

the

it from the

warm-weather use.

•

Drain antifreeze

coolant

(except

permanent type), flush the inside of cooling

system

city water).

marning.

surface of the hydraulic cylinder

oil

Replace lubricating oils for various

completely,

and

fil I with clean soft water (such as

to water drops collected on the

cylinder

cover

machine to be kept warm at night.

Particular attention should be given

the

warm,

units with the ones specified for

ground thereby preventing machine movement

•

3. As battery capacity drops at low

hard ground. If this is impossible,

becomes

perform the following without fail:

night.

Park the machine on concrete or

weather

be

damaged.

-37 -

s: s:0 m

I w co I

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free _operation and long machine life. Time and money spent for scheduled periodic maintenance will be amply compensated by prolonged machine operation and reduced operating cost.

All hourly figures given in the following descriptions are based on service meter readings. In practice, however, it is recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, it is necessary to some­ what shorten the maintenance intervals stated in this manual.

For details of handling and maintenance of the engine and related parts, see the engine operation manual.

-39-

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE

A For safety when carrying out maintenance.

Even simple operations, if carried out carelessly, can be the cause of injuries. At least the following points should be followed, but safety should always be borne in mind when carry­ ing out any operation.

• Wear a well-fitting hard hat, safety shoes and working clothes. If the nature of the work so requires, wear protective goggles, gloves or other protection.

Never wear loose or unbuttoned clothes as they may catch on protruding parts of the machine.

Never wear clothes covered in oil.

@

@

Unless you have special instructions to the contrary, maintenance should always be carried out with the engine stopped. If maintenance is carried out with the engine run­ ning, there must be two men present: one sitting in the opera­ tor's seat and the other one per­ forming the maintenance. Both should confirm the operation is safe.

When working with others, choose a group leader, decide the work procedure and work according to the leader's instructions. Check with the others before doing any­ thing. Do not move any part with­ out warning and do not perform any maintenance beyond the agreed work.

-40-

@

@

@

The body should always be lowered before carrying out any mainte­ nance. However, if the nature of the maintenance requires the dump body to be raised for inspection or maintenance.

Always stop the engine before washing the machine or charging oil.

Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame. As preparation in case of fire, always know the location and directions for use of fire extinguishers and other fire­ fighting equipment.

PRECAUTIONS FOR MAINTENANCE

• Flames should never be used instead of lamps.

Never use a naked flame to check leaks or the level of oil, fuel, anti­ freeze or electrolyte.

• Never smoke or bring naked flames near the battery. Never test the charge condition by striking the terminal with metal.

Before se-rvicing or charging the battery, always stop the engine, switch everything off and remove the vent caps. Before connecting or disconnecting the charger to the battery, always switch the charger OFF. • When working on top of the machine, be careful not to lose your balance and fall. Arrange things beforehand so that no one starts the engine or moves the machine by mistake.

• Never inspect the fan belt or attempt any maintenance when the engine is running.

Always stop the engine before carrying out maintenance on this or other moving parts, or near any moving parts.

• Always remember that the hydraulic oil circuit is under pres­ sure. When filling or draining the oil tank or carrying out inspection and maintenance, release the pressure first.

• When carrying out maintenance, pay careful attention to persons in the vicinity. In particular, do not allow anyone to approach the machine unnecessarily.

• When leaning over to inspect cases, there is a risk of dropping things in.

Before removing the covers to inspect such cases, empty every­ thing from your pockets. Be parti­ cularly careful to remove wrenches and nuts.

-41-

• Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail.

It is very dangerous if someone slips on floor plates.

• Always pay careful attention to those around you, particularly when using grinders, welding equip­ ment or hammers.

• Exhaust gas is dangerous. When working inside, be particularly care­ ful to have good ventilation.

• Special gauges are needed for checking hydraulic pressure.

Performing these checks or other difficult maintenance carelessly may cause accidents.

• Do not handle electrical equip­ ment while wearing wet clothes or gloves, or when standing in wet places. This may cause electric shock.

PRECAUTIONS FOR MAINTENANCE

GENERAL POINTS TO BE BORNE IN MIND WHEN CARRYING OUT MAINTENANCE @

Thoroughly wash the machine. In

@

particular, be careful to clean the

Before draining the oil, warm it up to a temperature of

filler caps, grease fittings and the area around the dipsticks. Be care­

•

Be

30 to 40 C.

particularly

0

careful

when

fu I not to let any dirt or dust into

removing the radiator cap or the

the system.

hydraulic oil tank filler cap.

• When changing the oil or filter, check the drained oil and filter for any

signs

of

excessive

metal

particles or other foreigr materials.

• When removing parts containing O­ rings, gaskets or seals, clean the

(lrJ)

Always use pure oil or grease, and

•

After replacing or cleaning the oil,

mounting surface and replace with

be sure to use clean containers, to

filter element or strainer, bleed the

new sealing parts.

prevent any dirt from getting in.

air from the circuit.

• Special

<ii

measuring

apparatus

1s

When checking or changing the oil,

• When the strainer is located in the

do it in a place free of dust, and

oil filler, the strainer must not be

sure.

prevent any dirt from getting into

removed while adding oil.

difficult maintenance work, carry­

the oil.

needed for testing hydraulic pres­ When

carrying

out

other

ing them out carelessly can cause � There should be neither too much nor too little lubricant. When add­ ing oil or checking the oil level, check that the oil is at the correct level.

11J

After greasing up, alw2'/S wipe off the old grease that was forced out.

-42 -

unexpected

accidents.

MAINTENANCE TABLE

MAINTENANCE TABLE ITEM

No.

SERVICE

PAGE

No.

ITEM

SERVICE

EVERY 25.HOURS SERVICE

CHECK BEFORE STARTING

PAGE ·-

a

Oil and water leak

Check

23

a

Lubricating

b

Nuts and bolts

Check and retighten

23

b

Transmission pump

Check

45

C

Electric wiring

Check and retighten

23

C

Track rubber

Adjust

45

d

Coolant

Check and supply

23

d

Control valve

Check noise

45

e

Dust indicator

Check

23

e

Friction parts

Clean

45

f

Fuel

Check and supply

24

g

Engine oil pan

Check and supply

24

h

Traveling motor and transmission pump

Check noise

24

a

Traveling motor

Change oil

46

i

Track rubber

Check tension

24

b

Hydraulic tank

Change oil

46

C

Nuts and bolts

Check and retighten

46

45

INITAl 100 HOURS SERVICE

INITIAL 25 HOURS SERVICE a

Line filter

Replace

45

-43 -

EVERY 300 HOURS SERVICE a

Hydraulic tank

Check oil level and supply

46

b

Traveling motor

Check oil level and supply

46

MAINTENANCE TABLE

No.

ITEM

SERVICE

PAGE

EVERY 500 HOURS SERVICE a

Hydraulic tank and line filter

1 Change oil and replace filter

EVERY 600 HOURS SERVICE a

Traveling motor

Change oil

47

-----·--- �·--

-

48

·--

-44-

INITIAL 25 HOURS SERVICE EVERY 25 HOURS SERVICE

EVERY 25 HOURS

INITIAL 25 HOURS SERVICE

SERVICE

a. LUBRICATING Apply grease to the grease fittings.

Perform the following maintenance after running the machine for the first 25 hours.

b. CHECK TRANSMISSION PUMP

a i. UNE FilTER For detaiIs of method of replacing, see the section on EVERY 500 HOU RS SERVICE.

c. ADJUST TRACK RUBBER d. CHECK CONTROL V Al VE FOR NOISE e. CLEAN THE FRICTION PARTS

-45-

INITIAL 100 HOURS SERVICE EVERY 300 HOURS SERVICE

INITIAL 100 HOURS SERVICE

Perform the following maintenance after running the machine for the first 100 hours.

EVERY 300 HOURS SERVICE

*

Maintenance for every 25 hours shou Id be carried out the same time.

a. HYDRAUU·C TANK

b. TRAVELING MOTOR

Stop the engine and wait for about 5 minutes before checking oil level.

1. Park the machine holding the drain plug (P) downward.

If the level of hydraulic oil is not between top H and bottom L Lines of

2. Remove plug (G) and check that the oil level· is near the bottom of

a. TRAVELING MOTOR, CHANGE Oil b. HYDRAULIC TANK, CHANGE OIL c. NUTS AND BOLTS, RETIGHTEN For details of the method of replacing, see the section on EVERY 500

HOURS

SERVICE.

and

600

HOURS

sight gauge

(G), pour in additional

hydraulic oil from filler (F).

the plug hole.

If necessary, remove plug (F) and add gear oil through the plug hole.

-46-

*

EVERY 500 HOURS SEVICE a. HYDRAUUC TANK AND UNE Fil TER

1. Remove cap (F).

2. Drain off oil from drain plug (P) at the bottom of the tank.

After draining, tighten the drain plug (P).

Maintenance for every 25 hours should be carried out at the same time.

3. Remove the filter case (1).

4. Replace the line filter. Install the filter case (1 ).

5. After replacing the filter, pour in the specified quantity of hydraulic oil from oil filler (F).

Refer to the section "FUEL, COOLANT AND LUBR !CANT".

*

-47-

EVERY 500 HOURS SERVICE

EVERY 600 HOURS SERVICE

EVERY 600 HOURS

*

SERVICE

a. TRAVEUNG MOTOR

1. Park the machine holding the drain plug (P) downward.

2. Drain the oil from drain plugs (P) on both sides of the machine.

After draining, tighten the drain plugs.

3. Then, supply new gear oil through oi I filier ( F) respectively to the specified level.

-48-

Maintenance for every 25 and 300 hours should be carried out at the same time.

TRACK RUBBER When it is· first used, the track rubber stretchi;s to settle the rubber and the core. If this stretching causes the track rubber to come off, install it and adjust it as follows.

1. Put jacks in contact with the front and rear of the frame, and raise the track rollers off the ground on the side where the track rubber has come off.

*

ADJUSTMENT 4. Push the holder in towards the front of the machine.

,A Do

not remove the grease nipple suddenly. It may fly off, so this is extremely dangerous.

in position securely.

3. Remove the nipple, and let the grease out from inside the cylinder.

,A The track rubber is extremely heavy so be careful when handling it.

6. Rotate the sprocket and push the track rubber.

under the frame to hold the chassis

reduce the internal pressure.

5. Fit the track rubber on the front sprocket first, then fit the rear part on the rear idler.

When doing this, put a support

2. Remove the grease nipple cover, then loosen the pressure release bolt until the grease comes out to

ADJUSTMENT

G,ease nipple

7'

��1

�I

��

�-hressure release /"-'.�11

Grease nipple cover

-491 -

ADJUSTMENT

7. Put a steel pipe in contact with the protruding part on the inside of the track rubber, then rotate the sprocket again.

8. Check that the track rubber is meshed securely with the sprocket and idler.

9. Tighten the nipple and pressure release bolt securely.

10. Pump in grease through the nipple with a grease pump, and adjust so that the distance from the rear of the track frame to the center of the rear idler is dimension A (See the table of the next page).

11. lnstal I the grease cover.

12 .. Check that the tension of the track rubber and the meshing with the sprocket and rollers is correct, then lower the machine to the ground.

Track frame

Holder

Pump in grease

*

Always rotate the sprocket in the direction shown by the arrow in the diagram below.

0

0

Steel pipes

Dimension A Track roller

- 50-

Track rubber

Rear idler

ADJUSTMENT

Table of dimensiorn A ' !

I

IVlach i ne mode I

Standard Value (mm)

MST-2200

435 ± 5

MST-2500

550 ±5

IVIST-3000

565 ± 5

MST-4000

565 ± 5

- 51 -

TROUBLE SHOOTING GUIDE

TR UBLE SHOOTING

UIDE

ENGINE Oil pressure caution lamp lights even when engine speed is increas­

Engine fails to st art.

sd after warm-up run.

e Insufficient fuel.

@ @

®

Air entrapped in fuel supply system.

Oil level in oil pan low (drawing air).

0

Oil filter element clogged.

• Fuel injection pump or nozzle defective.

Oi I leaks due to insufficient tightening or damage of oil pipe or

• Starter cannot crank engine fast enough.

pipe joint.

• Insufficient compression. c, Incorrect valve clearance.

Steam is emitted from top of radiator (from valve).

Indicator 01111 engine water gauge is in abnormal range.

Exhaust is white or bluish.

Cooling water insufficient or leaks.

• Excessive oil in oil pan.

0

Fan belt slackened.

• Improper fuel used.

®

Dust and scales accumulated in cooling system.

@

Radiator fins clogged or deformed.

®

@

Radiator filler cap loosened (when operating at high altitude).

Exhaust is black.

• Air cleaner element clogged.

• Nozzle defective.

@

Engine water gauge defective.

• Insufficient compression.

® Thermostat defective.

indicator on engine water gauge is in abnormal r ange.

Combustion occasionally gives stuttering sound.

eThermostat is defective.

@

@

Nozzle defective.

Engi_ne water gauge is defective.

Abnormal sound (in combustion or mechanical operation).

• Fuel of inferior qua I ity used. e Overheating occurs.

• Muffler broken. e Excess valve clearance.

-52-

TROUBLE SHOOTING GUIDE

ELECTRICAL SYSTEM Lamps are not bright despite maximum engine revolution. lamps flicker while engine is in operation. � Electrical wiring defective. <lill Belt tension out of adjustment.

Ammeter gives no deflection despite engine operation. @ Ammeter defective. © Electrical wiring defective.

Alternator has abnormal sound. l:lj Alternator defective.

Starting motor fails to turi:1 when starting switch is turned on. ® Electrical wiring defective. @ Battery charge low.

Starting motor pinion moves in cllnd out repeatedly. @ Battery charge low.

Cranking of engine by starting motor is too slow. @ Battery charge low. ® Starting motor defective.

Starting motor slips out of engagement before start-up of engine. ® Electrical wiring defective. @ Battery charge low.

-53-

STORAGE

STORAGE BEFORE STORAGE

To place the machine in storage for an extended period of time, the following measures must be taken to insure that it can be returned to opera­ tion with minimum of service.

• After every part is washed and dried, the machine shall be housed in a dry building. Never leave it outdoors.

In case it is indispensable to leave it outdoors, lay wood plates on the ground, and park the machine on the wood plates and cover it with canvas etc. e Completely fill fuel tank, lubricate and change oil before storage.

DURING STORAGE

• Apply a thin coat of grease to metal surface (hydraulic piston rods and front idler adjusting rods).

• As to batteries, remove the terminals and cover them, or remove them ·from the machine and store separately.

• When the ambient temperature is ° anticipated to drop below 0 C, always add antifreeze in the cooling water.

-54-

� Operate the engine and move the machine for a short distance once a month so that new oil film will be coated over movable parts and component surfaces. @ Before operating the working equipment, wipe off the grease on the hydraulic piston rod.

If it is unavoidably necessary to carry out rust-preventive operation while the machine is indoors, open up doors and windows to improve ventilation and prevent the gas poisoning.

A

STORAGE

AFTER STORAGE After storage (when it is kept with­ out cover or th rust-preventive opera­ tion once a month is not made), you shall apply the following treatment before operation.

• Loosen the drain plugs on oil pan and other cases and drain mixed water.

• You should request Komatsu dis­ tributor for following service. o Remove the cylinder head cover and lubricate sufficiently valves and rocker arms. And inspect the valve operation. o Remove the inlet port of the fuel injection pump, pour 0.5 to- 1 Q of the engine oil, and tighten it.

• • • • •

*

Bleed the air from the fuel system.

Change engine oil pan oil.

Replace all filters.

Clean cooling system.

After the engine is started, operate it until it is warm,ed up completely.

If the machine is stored for more than. a year without carrying out the monthly ru$t prevention opera­ tion, contact your distributor to have the engine overhauled.

-55-

FUEL, COOLANT AND LUBRICANTS

FUEL, C RESERVOIR

KIND OF FLUID

LANT AND LUBRICANTS -4

AMBIENT TEMPERATURE

14 10

20

50 10

32 0

I/

SAE

r-,_,

Engine oil pan

Engine oil

Specified amount

30 C

30

•·

.,...

lOW-30

SAE

I

CAPACITY (Q)

86°° F

)

10W

SAE

68 20

Hydraulic tank

Hydraulic oil

I #46

"

/

ASTM D 975 N0.1/ Fuel tank

Cooling system

Diesel fuel

Water

K

. . MST-2200: 27.0

24.0

MST-2500: 31.0

27.0

MST-3000: 42.0

37.0

MST-4000: 34.0

30.0

MST-2200: 120

110

MST-2500: 120

110

MST-3000: 140

130

MST-4000: 140

130

MST-2200: 170

-

I

#32

I

Refill capacity

#56

ASTM D975 No.2

Add antifreeze

- 56-

::.:·:

MST-2500: 210

-

MST-3000: 240

-

MST-4000: 240

-

MST-2200: 30.0

-

MST-3500: 36.0

-

MST-3000: 53.0

-

MST -4000: 51.0

-

FUEL, COOLANT AND LUBRICANTS

ASTM: American Society of Testing and Material Society of Automotive Engineers SAE: AP!: American Petroleum Institute Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

NOTE: ( 1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in th is manual.

Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur content

Change interval of oil in engine oil pan

0.5 to 1.00/o

1 /2 of regular interval

Above 1.00/o

1 /4 of regular interval

(2) When starting the engine in an atmospheric tempera­ ° ture of lower than 0 C, be sure to use engine oil of SAE 1 OW and SAE ·1 OW-30, even though an ° atmospheric temperature goes up to 10 C more or less in the day time.

(3) Use APi classification CD as engine oil and if API classificaticm CC, reduce the engine oil change inter­ val to half.

- 57 -

FUEL, COOLANT AND LUBRICANTS

Il I

t No.

I

i

Supplier Name

Engine Oii [CD] SAE10W, SAE30, SAE10W/30, SAE15VV/40

G,ear Oil

[Gl-·4, Gl-5]

SAE90, SAE140,

Grease [ lithium-Base]

NLGl-2

Anti-Freeze Coolant [ Ethylene Glycol Base] [Permanent Type]

1

AGIP

Diesel Sigma S Superdiesel Multigrade

ROTRA MP

GR M

2

AMOCO

Amoco 300

Multi-Purpose Gear

Super Permalube Grease

-

3

ARCO

Arco Fleet S-3 Plus

HD Gear Oil

Litholine H-EP

-

4

BP

Vanellus C-3

Hypoidgear EP Gear Oil EP

Energrease L2 Energrease LS2

Antifreeze

5

CALTEX

RPM Delo 300 RPM Delo 400

Multipurpose Thuban EP Universal Thuban

Marfak Multipurpose Marfak Al I Purpose

AF Engine Coolant

6

CASTROL

RX Super CRD

Hypoy, Hipress Hypoy B, Hypoy C

LM Grease

Antifreeze

CHEVRON

Delo 300 Delo 400

Universal Gear

Multi-Motive Grease Ultra-Duty Grease 2

8

ELF

Multiperformance 3C Performance 3C

Tranself EP T·anself EP Type B

Multi EPEXA 2

9

EXXON (ESSO)

Essolube 0-3 Essolube XD-3 Essolube XD-3 Extra

Gear Oil GP Gear Oil G:><

Multi Purpose Grease Beacon EP2

I

-- 58 -

11

'

Glacelf

-

FUEL, COOLANT AND LUBRICANTS

II

i No.

II

Supplier Name

'

10

!i

II

iI i'i

11

12

i. 13

!

Engine Oil [CD] SAE10W, SAE30, SAE10W/30, SAE15W/40

Gear Oil

[GL-4, Gl-5]

SAE90, SAE140,

Grease

Anti-Freeze Coolant

[ lithium-Base)

[ Ethylene Glycol Base]

NLG l-2

[Permanent Type]

GULF

Super Duty

MOBIL

Delvac 1300 Delvac 1400 Delvac 1400 Super

Mobilube HD Mobilube GX

PENNZOIL

Supreme Duty Fleet Multi-Duty

SHELL

Rimula Rimula X

Gulfcrown Grease No. 2 Gulfcrown EP Special Grease No. 2

Cruisemaster Antifreeze and Summer Coolant

Mobilgrease MP Mobilgrease 77 Mobilgrease 532 Mobilux EP2

Permazone

No.4092 Multi-Purpose No. 705 Multi-Purpose Gear No.4096 Wheel Bearing No. 707L No.4140 Spirax EP Spirax Heavy Duty

-

Sunoco Multi-Season Anti-Freeze

TEXACO

Ursa Super Plus Ursa Oil LA Ursa Super LA

Multigear Lubricant EP Thuban

Marfak All Purpose Marfak Multi Purpose 2

Startex AF & Summer Coolant

16

TOTAL

,L\ntifreeze

UNION

TOTAL EP Transmission TM

Multis EP2

17

Rubia S Rubia x

Guardol

MP Gear Lube LS

-59-

Unoba EP

i! fr,

i

!

Anti Freeze & Summer Coolant

Alvania Grease EP

I �

Sunfleet HP Sun Prestige 742 EP

15

I

1

Sunfleet GL-5

Sunfleet Dieselube XL Sunfleet Super C

I uI

ii

Multi-Purpose Gear Hypoid Gear All Purpose Type

SUN

14

i

:

i

I ''

11

-

FUEL, COOLANT AND LUBRICANTS

HYDRAULIC OIL (CONFORMING TO ISO)

Tropical region

Temperate region

Arctic region

Idemitsu

Daphne Super Hydraulic Fluid 56

Daphne Hydraulic Fluid

Daphne Hydraulic Fluid 18AV

Kyodo

Hydlux 68

Hlydlux 32

Hydro W32

Pentalube

Penta HR-56

Penta HR-32

Penta HR-22

Esso

Teresso 68

Teressa 32

Nuto H15

Shell

Tellus oil 56

Tellus oil 32

Tellus oil T37

Mobil

D.T.E. Heavy Medium

D.T.E. Light

D.T.E. 13

Supplier Name

32

-60-

SPECIFICATIONS VIBRATION: Whole Body Vibration The weighted root mean square vibration acceleration to which the operator is subjected through the seat is unlikely to exceed 0.6ms2.Test are conducted under relatively harsh conditions, and in many work conditions, lower magnitudes of acceleration can be anticipated. Only in certain particularly severe conditions is this value likely to be exceeded.

Hand/arm Vibration This machine does not transmit vibration greater than 2.5ms2 to the operators hand or arms.

NOISE LEVELS:

MOROOKA 2200

Noise Level at Operator's Ear External Noise Level

(LpA) (LwA)

82 98

SPECIFICATIONS

VIBRATION: Whole Body Vibration The weighted root mean square vibration acceleration to which the operator is subjected through the seat is unlikely to exceed 0.6ms2.Test are conducted under relatively harsh conditions, and in many work conditions, lower magnitudes of acceleration can be anticipated. Only in certain particularly severe conditions is this value likely to be exceeded.

Hand/arm Vibration This machine does not transmit vibration greater than 2.5ms2 to the operators hand or arms.

NOISE LEVELS:

MOROOKA 2500, 2600, 3000

Noise Level at Operator's Ear External Noise Level

(LpA) (LwA)

86 98